Light tube and power supply circuit

ABSTRACT

A replacement light tube for replacing a fluorescent light tube includes a bulb portion extending between a first end and a second end, the bulb portion comprising a support structure, a plurality of white light emitting diodes (LEDs) and an elongate light-transmissive cover. The support structure has a first surface extending between the first end and the second end. The plurality of LEDs are supported by the first surface and arranged between the first end and the second end. The elongate light-transmissive cover extends between the first end and the second end and over the first surface of the support structure. A first end cap and a second end cap are disposed on the first end and the second end, respectively, each configured to fit with a socket for a fluorescent light tube. A power supply circuit is configured to provide power to the plurality of LEDs. The plurality of LEDs are arranged to emit light through the elongate light-transmissive cover and at least a portion of the power supply circuit is packaged inside at least one of the end caps.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/187,456, filed Jun. 20, 2016, which is a continuation of U.S. patentapplication Ser. No. 14/865,325, filed Sep. 25, 2015 and issued as U.S.Pat. No. 9,416,923 on Aug. 16, 2016, which is a continuation of U.S.patent application Ser. No. 14/669,963, filed on Mar. 26, 2015 andissued as U.S. Pat. No. 9,222,626 on Dec. 29, 2015, which is acontinuation of U.S. patent application Ser. No. 14/299,909, filed onJun. 9, 2014 and issued as U.S. Pat. No. 9,006,990 on Apr. 14, 2015 anda continuation of U.S. patent application Ser. No. 14/299,915, filedJun. 9, 2014 and issued as U.S. Pat. No. 9,006,993 on Apr. 14, 2015,which are continuations of U.S. patent application Ser. No. 13/777,331,filed Feb. 26, 2013 and issued as U.S. Pat. No. 8,866,396 on Oct. 21,2014, which is a continuation of U.S. patent application Ser. No.12/965,019, filed Dec. 10, 2010 and issued as U.S. Pat. No. 8,382,327 onFeb. 26, 2013, which is a continuation of U.S. patent application Ser.No. 11/085,744, filed Mar. 21, 2005 and issued as U.S. Pat. No.8,247,985 on Aug. 21, 2012, which is a continuation of U.S. patentapplication Ser. No. 09/782,375, filed Feb. 12, 2001 and issued as U.S.Pat. No. 7,049,761 on May 23, 2006, which claims the benefit of U.S.Provisional Application No. 60/181,744 filed Feb. 11, 2000.

FIELD OF THE INVENTION

The present invention relates to a light tube illuminated by LEDs (lightemitting diodes) which are packaged inside the light tube and powered bya power supply circuit.

BACKGROUND OF THE INVENTION

Conventional fluorescent lighting systems include fluorescent lighttubes and ballasts. Such lighting systems are used in a variety oflocations, such as buildings and transit buses, for a variety oflighting purposes, such as area lighting or backlighting. Althoughconventional fluorescent lighting systems have some advantages overknown lighting options, such as incandescent lighting systems,conventional fluorescent light tubes and ballasts have severalshortcomings. Conventional fluorescent light tubes have a short lifeexpectancy, are prone to fail when subjected to excessive vibration,consume high amounts of power, require a high operating voltage, andinclude several electrical connections which reduce reliability.Conventional ballasts are highly prone to fail when subjected toexcessive vibration. Accordingly, there is a desire to provide a lighttube and power supply circuit which overcome the shortcomings ofconventional fluorescent lighting systems. That is, there is a desire toprovide a light tube and power supply circuit which have a long lifeexpectancy, are resistant to vibration failure, consume low amounts ofpower, operate on a low voltage, and are highly reliable. It would alsobe desirable for such a light tube to mount within a conventionalfluorescent light tube socket.

SUMMARY OF THE INVENTION

Embodiments of a replacement light tube for replacing a fluorescentlight tube are disclosed herein. In one embodiment, the replacementlight tube for replacing a fluorescent light tube includes a bulbportion extending between a first end and a second end, the bulb portioncomprising a support structure, a plurality of white light emittingdiodes (LEDs) and an elongate light-transmissive cover. The supportstructure has a first surface extending between the first end and thesecond end. The plurality of LEDs are supported by the first surface andarranged between the first end and the second end. The elongatelight-transmissive cover extends between the first end and the secondend and over the first surface of the support structure. A first end capand a second end cap are disposed on the first end and the second end,respectively, each configured to fit with a socket for a fluorescentlight tube. A power supply circuit is configured to provide power to theplurality of LEDs. The plurality of LEDs are arranged to emit lightthrough the elongate light-transmissive cover and at least a portion ofthe power supply circuit is packaged inside at least one of the endcaps.

In another embodiment, the replacement light tube includes a bulbportion extending between a first end and a second end, the bulb portioncomprising a support structure, a plurality of white light emittingdiodes (LEDs) and an elongate light-transmissive cover. The supportstructure has a first surface extending between the first end and thesecond end. The plurality of LEDs are supported by the first surface andarranged between the first end and the second end, the LEDs beingdisposed along a base of a channel defined by the support structure. Theelongate light-transmissive cover extends between the first end and thesecond end and over the first surface of the support structure. A firstend cap and a second end cap are disposed on the first end and thesecond end, respectively, each configured to fit with a socket for afluorescent light tube. A power supply circuit is configured to providepower to the plurality of LEDs, the power supply circuit comprising arectifier configured to receive alternating current (AC) input from aballast and to provide direct current (DC) output. The plurality of LEDsare arranged to emit light through the elongate light-transmissive coverand at least a portion of the power supply circuit is packaged inside atleast one of the end caps.

These and other embodiments will be discussed in additional detailhereafter.

BRIEF DESCRIPTION OF THE DRAWINGS

The description herein makes reference to the accompanying drawingswherein like reference numerals refer to like parts throughout theseveral views, and wherein:

FIG. 1 is a line drawing showing a light tube, in perspective view,which in accordance with the present invention is illuminated by LEDspackaged inside the light tube;

FIG. 2 is a perspective view of the LEDs mounted on a circuit board;

FIG. 3 is a cross-sectional view of FIG. 2 taken along lines 3-3;

FIG. 4 is a fragmentary, perspective view of one embodiment of thepresent invention showing one end of the light tube disconnected fromone end of a light tube socket;

FIG. 5 is an electrical block diagram of a first power supply circuitfor supplying power to the light tube;

FIG. 6 is an electrical schematic of a switching power supply typecurrent limiter;

FIG. 7 is an electrical block diagram of a second power supply circuitfor supplying power to the light tube;

FIG. 8 is an electrical block diagram of a third power supply circuitfor supplying power to the light tube;

FIG. 9 is a fragmentary, perspective view of another embodiment of thepresent invention showing one end of the light tube disconnected fromone end of the light tube socket; and

FIG. 10 is an electrical block diagram of a fourth power supply circuitfor supplying power to the light tube.

DETAILED DESCRIPTION

FIG. 1 is a line drawing showing a light tube 20 in perspective view. Inaccordance with the present invention, the light tube 20 is illuminatedby LEDs 22 packaged inside the light tube 20. The light tube 20 includesa cylindrically shaped bulb portion 24 having a pair of end caps 26 and28 disposed at opposite ends of the bulb portion. Preferably, the bulbportion 24 is made from a transparent or translucent material such asglass, plastic, or the like. As such, the bulb material may be eitherclear or frosted.

In a preferred embodiment of the present invention, the light tube 20has the same dimensions and end caps 26 and 28 (e.g. electrical malebi-pin connectors, type G13) as a conventional fluorescent light tube.As such, the present invention can be mounted in a conventionalfluorescent light tube socket.

The line drawing of FIG. 1 also reveals the internal components of thelight tube 20. The light tube 20 further includes a circuit board 30with the LEDs 22 mounted thereon. The circuit board 30 and LEDs 22 areenclosed inside the bulb portion 24 and the end caps 26 and 28.

FIG. 2 is a perspective view of the LEDs 22 mounted on the circuit board30. A group of LEDs 22, as shown in FIG. 2, is commonly referred to as abank or array of LEDs. Within the scope of the present invention, thelight tube 20 may include one or more banks or arrays of LEDs 22 mountedon one or more circuit boards 30. In a preferred embodiment of thepresent invention, the LEDs 22 emit white light and, thus, are commonlyreferred to in the art as white LEDs. In FIGS. 1 and 2, the LEDs 22 aremounted to one surface 32 of the circuit board 30. In a preferredembodiment of the present invention, the LEDs 22 are arranged to emit orshine white light through only one side of the bulb portion 24, thusdirecting the white light to a predetermined point of use. Thisarrangement reduces light losses due to imperfect reflection in aconventional lighting fixture. In alternative embodiments of the presentinvention, LEDs 22 may also be mounted, in any combination, to the othersurfaces 34, 36, and/or 38 of the circuit board 30.

FIG. 3 is a cross-sectional view of FIG. 2 taken along lines 3-3. Toprovide structural strength along the length of the light tube 20, thecircuit board 30 is designed with a H-shaped cross-section. To produce apredetermined radiation pattern or dispersion of light from the lighttube 20, each LED 22 is mounted at an angle relative to adjacent LEDsand/or the mounting surface 32. The total radiation pattern of lightfrom the light tube 20 is effected by (1) the mounting angle of the LEDs22 and (2) the radiation pattern of light from each LED. Currently,white LEDs having a viewing range between 6° and 45° are commerciallyavailable.

FIG. 4 is a fragmentary, perspective view of one embodiment of thepresent invention showing one end of the light tube 20 disconnected fromone end of a light tube socket 40. Similar to conventional fluorescentlighting systems and in this embodiment of the present invention, thelight tube socket 40 includes a pair of electrical female connectors 42and the light tube 20 includes a pair of mating electrical maleconnectors 44.

Within the scope of the present invention, the light tube 20 may bepowered by one of four power supply circuits 100, 200, 300, and 400. Afirst power supply circuit includes a power source and a conventionalfluorescent ballast. A second power supply circuit includes a powersource and a rectifier/filter circuit. A third power supply circuitincludes a DC power source and a PWM (Pulse Width Modulation) circuit. Afourth power supply circuit powers the light tube 20 inductively.

FIG. 5 is an electrical block diagram of a first power supply circuit100 for supplying power to the light tube 20. The first power supplycircuit 100 is particularly adapted to operate within an existing,conventional fluorescent lighting system. As such, the first powersupply circuit 100 includes a conventional fluorescent light tube socket40 having two electrical female connectors 42 disposed at opposite endsof the socket. Accordingly, a light tube 20 particularly adapted for usewith the first power supply circuit 100 includes two end caps 26 and 28,each end cap having the form of an electrical male connector 44 whichmates with a corresponding electrical female connector 42 in the socket40.

The first power supply circuit 100 also includes a power source 46 and aconventional magnetic or electronic fluorescent ballast 48. The powersource 46 supplies power to the conventional fluorescent ballast 48.

The first power supply circuit 100 further includes a rectifier/filtercircuit 50, a PWM circuit 52, and one or more current-limiting circuits54. The rectifier/filter circuit 50, the PWM circuit 52, and the one ormore current-limiting circuits 54 of the first power supply circuit 100are packaged inside one of the two end caps 26 or 28 of the light tube20.

The rectifier/filter circuit 50 receives AC power from the ballast 48and converts the AC power to DC power. The PWM circuit 52 receives theDC power from the rectifier/filter circuit 50 and pulse-width modulatesthe DC power to the one or more current-limiting circuits 54. In apreferred embodiment of the present invention, the PWM circuit 52receives the DC power from the rectifier/filter circuit 50 andcyclically switches the DC power on and off to the one or morecurrent-limiting circuits 54. The DC power is switched on and off by thePWM circuit 52 at a frequency which causes the white light emitted fromthe LEDs 22 to appear, when viewed with a “naked” human eye, to shinecontinuously. The PWM duty cycle can be adjusted or varied by controlcircuitry (not shown) to maintain the power consumption of the LEDs 22at safe levels.

The DC power is modulated for several reasons. First, the DC power ismodulated to adjust the brightness or intensity of the white lightemitted from the LEDs 22 and, in turn, adjust the brightness orintensity of the white light emitted from the light tube 20. Optionally,the brightness or intensity of the white light emitted from the lighttube 20 may be adjusted by a user. Second, the DC power is modulated toimprove the illumination efficiency of the light tube 20 by capitalizingupon a phenomenon in which short pulses of light at high brightness orintensity to appear brighter than a continuous, lower brightness orintensity of light having the same average power. Third, the DC power ismodulated to regulate the intensity of light emitted from the light tube20 to compensate for supply voltage fluctuations, ambient temperaturechanges, and other such factors that affect the intensity of white lightemitted by the LEDs 22. Fourth, the DC power is modulated to raise thevariations of the frequency of light above the nominal variation of 120to 100 Hz thereby reducing illumination artifacts caused by lowfrequency light variations, including interactions with video screens.Fifth, the DC power may optionally be modulated to provide an alarmfunction wherein light from the light tube 20 cyclically flashes on andoff

The one or more current-limiting circuits 54 receive the pulse-widthmodulated or switched DC power from the PWM circuit 52 and transmit aregulated amount of power to one or more arrays of LEDs 22. Eachcurrent-limiting circuit 54 powers a bank of one or more white LEDs 22.If a bank of LEDs 22 consists of more than one LED, the LEDs areelectrically connected in series in an anode to cathode arrangement. Ifbrightness or intensity variation between the LEDs 22 can be tolerated,the LEDs can be electrically connected in parallel.

The one or more current-limiting circuits 54 may include (1) a resistor,(2) a current-limiting semiconductor circuit, or (3) a switching powersupply type current limiter.

FIG. 6 is an electrical schematic of a switching power supply typecurrent limiter 56. The limiter 56 includes an inductor 58, electricallyconnected in series between the PWM circuit 52 and the array of LEDs 22,and a power diode 60, electrically connected between ground 62 and a PWMcircuit/inductor node 64. The diode 60 is designed to begin conductionafter the PWM circuit 52 is switched off. In this case, the value of theinductor 58 is adjusted in conjunction with the PWM duty cycle toprovide the benefits described above. The switching power supply typecurrent limiter 56 provides higher power efficiency than the other typesof current-limiting circuits listed above.

FIG. 7 is an electrical block diagram of a second power supply circuit200 for supplying power to the light tube 20. Similar to the first powersupply circuit 100, the second power supply circuit 200 includes aconventional fluorescent light tube socket 40 having two electricalfemale connectors 42 disposed at opposite ends of the socket 40.Accordingly, a light tube 20 particularly adapted for use with thesecond power supply circuit 200 includes two end caps 26 and 28, eachend cap having the form of an electrical male connector 44 which mateswith a corresponding electrical female connector 42 in the socket 40.

In the second power supply circuit 200, the power source 46 suppliespower directly to the rectifier/filter circuit 50. The rectifier/filtercircuit 50, the PWM circuit 52, and the one or more current-limitingcircuits 54 operate as described above to power the one or more arraysof LEDs 22. The rectifier/filter circuit 50, the PWM circuit 52, and theone or more current-limiting circuits 54 of the second power supplycircuit 200 are preferably packaged inside the end caps 26 and 28 or thebulb portion 24 of the light tube 20 or inside the light tube socket 40.

FIG. 8 is an electrical block diagram of a third power supply circuit300 for supplying power to the light tube 20. Similar to the first andsecond power supply circuits 100 and 200, the third power supply circuit300 includes a conventional fluorescent light tube socket 40 having twoelectrical female connectors 42 disposed at opposite ends of the socket40. Accordingly, a light tube 20 particularly adapted for use with thethird power supply circuit 300 includes two end caps 26 and 28, each endcap having the form of an electrical male connector 44 which mates witha corresponding electrical female connector 42 in the socket 40.

The third power supply circuit 300 includes a DC power source 66, suchas a vehicle battery. In the third power supply circuit 300, the DCpower source 66 supplies DC power directly to the PWM circuit 52. ThePWM circuit 52 and the one or more current-limiting circuits 54 operateas described above to power the one or more arrays of LEDs 22. In thethird power supply circuit 300, the PWM circuit 52 is preferablypackaged in physical location typically occupied by the ballast of aconventional fluorescent lighting system while the one or morecurrent-limiting circuits 54 and LEDs 22 are preferably packaged insidethe light tube 20, in either one of the two end caps 26 or 28 or thebulb portion 24.

FIG. 9 is a fragmentary, perspective view of another embodiment of thepresent invention showing one end of the light tube 20 disconnected fromone end of the light tube socket 40. In this embodiment of the presentinvention, the light tube socket 40 includes a pair of brackets 68 andthe light tube 20 includes a pair of end caps 26 and 28 which mate withthe brackets 68.

FIG. 10 is an electrical block diagram of a fourth power supply circuit400 for supplying power to the light tube 20. Unlike the first, second,and third power supply circuits 100, 200, and 300 which are poweredthrough direct electrical male and female connectors 44 and 42, thefourth power supply circuit 400 is powered inductively. As such, thefourth power supply circuit 400 includes a light tube socket 40 havingtwo brackets 68 disposed at opposite ends of the socket 40. At least onebracket 68 includes an inductive transmitter 70. Accordingly, a lighttube 20 particularly adapted for use with the fourth power supplycircuit 400 has two end caps 26 and 28 with at least one end capincluding an inductive receiver or antenna 72. When the light tube 20 ismounted in the light tube socket 40, the at least one inductive receiver72 in the light tube 20 is disposed adjacent to the at least oneinductive transmitter 70 in the light tube socket 40.

The fourth power supply circuit 400 includes the power source 46 whichsupplies power to the at least one inductive transmitter 70 in the lighttube socket 40. The at least one transmitter 70 inductively suppliespower to the at least one receiver 72 in one of the end caps 26 and/or28 of the light tube 20. The at least one inductive receiver 72 suppliespower to the rectifier/filter circuit 50. The rectifier/filter circuit50, PWM circuit 52, and the one or more current-limiting circuits 54operate as described above to power the one or more arrays of LEDs 22.In this manner, the light tube 20 is powered without direct electricalconnection.

1.-20. (canceled)
 21. A method for providing a light tube for mountingwithin a conventional fluorescent light tube socket, the methodcomprising: disposing the plurality of light emitting diodes on a rigidsupport structure, the rigid support structure comprising spaced-apartsidewalls forming a channel and a planar portion having a first surfaceextending in the channel formed by the sidewalls, the light emittingdiodes being disposed on the first surface; disposing the supportstructure and plurality of light emitting diodes within a tubularhousing comprising a transmissive cover for the light emitting diodes,wherein at least a portion of the sidewalls contact an interior surfaceof the tubular housing; and disposing a pair of end caps at oppositeends of the tubular housing, each end cap configured to fit with theconventional fluorescent light tube socket.
 22. The method of claim 21,wherein disposing the plurality of light emitting diodes relative to thelight transmissive cover comprises covering the light emitting diodeswith the light transmissive cover of the tubular housing.
 23. The methodof claim 22, wherein the portion of the sidewalls contact the lighttransmissive cover when the support structure is disposed within thetubular housing.
 24. The method of claim 21, wherein, when disposedwithin the tubular housing, the support structure divides the tubularhousing into a first space in which the plurality of light emittingdiodes are housed and a second space defined by the planar portion, thesidewalls and the interior surface of the tubular housing.
 25. Themethod of claim 21, wherein the planar portion is integral with thesidewalls.
 26. The method of claim 21, wherein the sidewalls aregenerally perpendicular to the planar portion.
 27. The method of claim21, wherein the support structure comprises a circuit board and thelight emitting diodes are mounted on a surface of the circuit board. 28.The method of claim 21, wherein the power supply circuit is configuredto regulate the intensity of light emitted from the plurality of lightemitting diodes to compensate for voltage fluctuations from the powersource during operation of the light tube.
 29. The method of claim 21,further comprising connecting a power supply circuit to the plurality oflight emitting diodes and disposing the power supply circuit within thelight tube.
 30. The method of claim 29, wherein the power supply circuitis configured to regulate the intensity of light emitted from theplurality of light emitting diodes to compensate for ambient temperaturechanges during operation of the light tube.
 31. The method of claim 29,wherein the power supply circuit comprises a pulse width modulatorconfigured to receive the power from the power source and provideregulated power to the light emitting diodes by pulse-width modulatingthe received power during operation of the light tube.
 32. The method ofclaim 31, wherein the power supply circuit comprises a current limiterhaving an inductive element electrically coupled between the pulse widthmodulator and at least some of the plurality of light emitting diodes,the current limiter configured to receive power from the pulse widthmodulator and to transmit power to the at least some of the plurality oflight emitting diodes during operation of the light tube.
 33. The methodof claim 29, wherein the power supply circuitry is configured to switchpower to the plurality of light emitting diodes on and off at afrequency and to cause the light emitted from the plurality of lightemitting diodes to appear, when viewed by a human eye, to shinecontinuously during operation of the light tube.
 34. The method of claim29, wherein at least some components of the power supply circuits aredisposed within at least one of the end caps.
 35. The method of claim29, wherein the power supply circuit comprises a rectifier configured toreceive alternating current (AC) input and to provide direct current(DC) output during operation of the light tube.
 36. The method of claim35, wherein the rectifier is arranged to provide the DC output to apulse width modulator during operation of the light tube.
 37. The methodof claim 21, wherein each end cap comprises a bi-pin connector forconnecting with the conventional fluorescent light tube socket.
 38. Themethod of claim 37, further comprising connecting a power supply circuitto the plurality of light emitting diodes and electrically connectingthe power supply circuit to the bi-pin connector of at least one endcap.
 39. The method of claim 21, wherein the light emitting diodes arearranged along an axis extending between the end caps.
 40. The method ofclaim 21, wherein the light emitting diodes are white light emittingdiodes.
 41. The method of claim 21, wherein the light transmissive coveris a tube formed from a transparent or translucent material.
 42. Themethod of claim 21, wherein the tubular housing is a cylindrical tube.43. The method of claim 21, wherein the light emitting diodes comprisesa first light emitting diode and a second light emitting diode, thefirst light emitting diode being the light emitting diode closest to anend of the rigid support structure and the second light emitting diodebeing the next closest to the end of the rigid support structure, thefirst and second light emitting diodes being are disposed such that ashortest distance between the first light emitting diode and the secondlight emitting diode is less than a shortest distance between the firstlight emitting diode and the end of the rigid support structure.